Wet pulping system and method for producing cellulosic insulation with low ash content

ABSTRACT

Apparatus and method for recovering organic cellulosic fibers from landfill materials (such as post consumer, municipal and industrial waste materials). The apparatus and method selectively introduces waste materials containing organic cellulosic fibers into a size reduction machine. The pre-cleaned waste materials are conveyed to a tank, drum, or tunnel type fiber recovery apparatus. The waste materials are subjected to mechanical and fluid fiberization for a selected period of time to produce useful products, such as cellulosic insulation with a total ash content equal to or less than 10%, as well animal and fowl bedding products that is substantially devoid of moisture content, among other products.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of, and claims priority to,co-pending U.S. patent application Ser. No. 11/610,977, filed Dec. 14,2006, and now U.S. Pat. No. 7,758,719, which application claims thebenefit of U.S. Provisional Application No. 60/750,788, filed on Dec.16, 2005, the specifications of each of which are incorporated herein intheir entireties.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to systems and methods for recoveringcellulosic fiber from waste products such as landfill materials, e.g.,post-consumer, municipal, and industrial waste materials, and to systemsand methods for removing and recovering adverse inorganic chemicals andmaterials from such products in order to produce cellulosic thermalinsulation with certain performance and ash content characteristics, aswell as to produce material used in fowl and animal bedding with certaindesirable characteristics and filler materials for various organic andinorganic compositions.

2. Related Art

A widely used insulating material for homes and other buildings iscommonly manufactured by fiberizing waste (primarily clean recyclednewsprint; commonly referred to as “old newsprint” or “ONP”) that hasfew contaminates (such as plastic, string, metal foil and glass), insuitable equipment (such as a hammer mill or a disc refiner), whileadding dry fire retardant chemicals (such as boric acid and ammoniumsulfate).

Cellulose insulation has been produced using a variety of manufacturingequipment for approximately 80 years. Methodology has only variedslightly over the years using a combination of paper shredders,hammer-mills with sizing screens and disc refiners to produce a marketacceptable product.

The quality of cellulose insulation is defined technically as compliancewith the industry standard ASTM C739. Products are labeled with testingresults; normally from a third party testing facility, and certaincomponents are tested regularly by manufacturers for quality assurance.The attributes traditionally tested in-house by manufacturers includetwo fire resistance tests; radiant panel and smoldering combustion, pHto confirm fire retardant chemical formulation and settled density.

Customers assume compliance with ASTM C739; however consider a qualityproduct as one that provides the coverage per package that is advertised(product density and package weight), product texture or particle size,amount of contaminants and dust level.

Product coverage dictates the economic impact to the customer of usingthe product. The product density is an important indicator of aproduct's eventual coverage. A product's density is impacted by thefiber quality of the ONP, the condition of wear surfaces in the discrefiner and chemical content. Particle size is dictated by the conditionof wear surfaces in the disc refiner and the gap settings within therefiner. Contaminants are a factor of the quality of the ONP and minimalprocess separation devices. Dust levels are dictated by the quality ofONP, wear surface condition in the disc refiner, chemical content andlevel of inorganic components from the ONP source.

In recent years it has become more difficult to obtain clean wastenewsprint at acceptable prices in order to manufacture cellulosicinsulation using the common dry manufacturing process mentioned above(which process is currently utilized by the entire U.S. cellulosicinsulation market). There are numerous less expensive cellulosic fibersources available today that all have non-desirable compositions or aremixed with non-desirable materials that cannot be used to manufacturecellulosic insulation utilizing the traditional dry production processto produce cellulosic insulation that meets Federal Specificationrequirements (including those by the U.S. Consumer Product SafetyCommission and Federal Specifications such as ASTM C739-91, ASTMC739-03, ASTM E970, ASTM C518, ASTM C1148, ASTM D778 and HH-I-515D). Inaddition, the cost of clean dry waste newsprint has risen to levels thatmake it difficult to economically and competitively manufactureacceptable cellulosic insulation. This is due to the increase in demandfor clean recycled newsprint, primarily from Asia.

Modern conventional processes require the use of #8 or #9 old newspapers(ONP) that are considered a high grade of recycled fiber. The entireprocess requires the use of dry ONP that has minimal contaminants(plastic, metal waste, etc). ONP is metered through a primary shredder,through a secondary hammer-mill and then a disc refiner to create thefinished product. Fire retardant chemicals are metered through apulverizer and added to the process normally before the disc refiner.

The most significant challenge facing conventional processes is thequality and composition of ONP. Papermaking technology has advanced tousing recycled ONP as the primary source of fiber rather than virginsources (trees). The addition of various fillers (primarily calciumcarbonate; CaCO₃) has caused difficulty for cellulose insulationmanufacturers to maintain good (lower) densities and a low-dust levelproduct. The measurement of a product's thermal performance (R-value) ishindered by high densities and high levels of inorganic particles.Additionally, the advent of single-stream recycling programs hassignificantly reduced the availability of high quality ONP, one that isvirtually free of contaminants and is dry.

Attempts to utilize a wet process to separate cellulosic fibers fromcontaminates found with or adhering to the cellulosic fibers have beenmade in the past. The common approach has been to utilize a standardhydro-pulping device to separate the cellulosic fibers from thecontaminates, utilizing a harsh mechanical process that also degradesthe fibers and leaves the contaminates in very small pieces that aredifficult or impossible to remove. This method has not proven to besuccessful commercially to produce a cellulose based fiber insulation.

There are many types of waste materials that contain cellulosic fibersthat cannot be recycled in conventional processes and are sent tolandfills because the fibers are either (i) laminated and contain layersof plastic or metal foil (such as milk cartons and industrial scrap fromaluminum roll boxes), and/or (ii) mixed with plastics, metal and/orglass to such a degree that it cannot be used. In addition, currentpapermaking research is directed to increasing the calcium carbonateloading, from approximately 5 to 7%, to a much higher 15 to 20% loadingby reacting in situ calcium carbonate not only on the surface of thefibers but also in the hollow spaces within the fibers.

Paper manufacturers continue to increase the use of calcium carbonate asa major component in their papermaking processes to facilitate the useof greater amounts of shorter recycled fibers and thereby retain thedesired sheet strength and other desirable physical properties. Itshould be noted that typical waste paper recycling processes, by design,retain these fillers as a necessary component to retain the physicalproperties of recycled paper stock. However, it is desirable to removethese fillers in order to produce acceptable products for uses otherthan the recycling of waste paper back into reconstituted (recycled)paper stock. Current levels of calcium carbonate and other fillers alongwith the increasing use of short fibers (fines) in the recycled wastepaper stream is presenting a major problem for dry process cellulosicinsulation manufacturers today. Products increasingly have a highernuisance dust content, have higher bulk densities, and lower heat lossresistance values.

In order for a quality cellulosic thermal insulation to be manufacturedwith today's recoverable waste paper and fiber sources, the greaterportion of the calcium carbonate's and other fillers should be removed,for example, by dissolving the calcium carbonate from within and on thefiber surfaces, and then precipitate and remove this contaminant andother fillers. The manufacture of quality cellulosic thermal insulationwill become increasingly more difficult using the processes andtechnologies that are available today.

There have been several attempts to produce cellulosic insulation fromwaste fibers using systems that utilize a combination of wet and dryprocess steps. For example, U.S. Pat. No. 6,155,020, to Deem, issuedDec. 5, 2000, discloses a method for producing insulation out ofrecycled carpet utilizing a dry shredding process to separate the usefulfibers from the carpet backing and other non-used materials.

U.S. Pat. No. 5,714,040, to Poy et al., issued Feb. 3, 1998, discloses amethod for recovering fiber from printed newspaper by loading the wastepaper and water into a continuous batch fiber recovery apparatus. Allare agitated within the apparatus to form a pulp fiber slurry whileintroducing de-inking and agglomerating compositions to causes inkparticles associated with the printed newspaper to separate. These inkparticles are then removed from the pulp using separation techniques.

U.S. Pat. No. 5,272,852, to Fortin et al., issued Dec. 28, 1993,discloses a process where an insulating pulp is formed from debarkedtrees, primarily black spruce, using a chemi-thermo-mechanical pulpingprocess to make a fluffed form or to form a compressed sheet that islater defiberized utilizing a portable insulating pulp applicator. Theresulting product has a fire retardant additive in the range of 10%-25%by weight.

U.S. Pat. No. 5,084,307, to Nishimoto et al., issued Jan. 28, 1992,discloses a flame retardant vegetable fiber material and a process forthe production of this material. Vegetable fiber is immersed into twoinorganic solutions to fill the inherent gaps of the fiber to create aninsoluble and incombustible inorganic compound that can be used as afire retardant material such as asbestos or rock wool. The inorganicsolutions utilized include first, magnesium chloride, barium chloride,calcium carbonate, aluminum chloride, aluminum borate and aluminumsulfate and second, ammonium sulfate, ammonium pyrophosphate, ammoniummagnesia and boric acid soda.

U.S. Pat. No. 4,454,992, to Draganov, issued Jun. 19, 1984, discloses acombination wet/dry system that utilizes an aqueous solution ofnon-hydroscopic fire retardants to produce cellulosic insulation. Theprocess described uses a predominately dry process to grind shreddednewsprint and add fire retardant chemicals in a wet form with elevatedtemperature to utilize a low amount of fire retardant chemicals to meetcommercial fire retardancy requirements.

There also have been attempts to produce non-insulation products fromwaste fibers that focus on separating the fibers from non-fibrousmaterials. For example, U.S. Pat. No. 4,737,238, to de Ruvo, et al.,issued Apr. 12, 1988, discloses a process for treating waste papercontaining aluminum and having high lignin content by de-lignifying andpulping the waste paper for reuse in papermaking.

U.S. Pat. No. 4,760,717, to Ponzielli, issued Aug. 2, 1998, discloses aprocess that uses a hydro-pulping like apparatus to separate plasticfilm from cellulosic fibers goods. This process acts like a blender toshred the materials during processing.

U.S. Pat. No. 6,238,516, to Watson et al., issued May 29, 2001,discloses a system and process whereby pulping machines are utilized torecycle plastic and cellulosic fibers from disposed diapers. The processutilizes a similar fiber recovery apparatus to separate the plastic fromthe cellulosic fibers, then clean the plastic and cellulosic fibers fromall waste material for further use.

Despite these known approaches, and the increasing need for qualitywaste products, no commercial process has been developed to producecellulosic insulation out of waste paper materials that are contaminatedwith a high degree of calcium carbonate, fines, and other non-organicmaterials (such as plastics, foils, glass, metal and other non-organiccontent), and materials that are contained in, commingled with, orlaminated to the cellulosic fibers or waste fibers. These wastematerials are currently sent to a landfill and landfills are becomingincreasingly scarce and difficult to build.

In regard to animal and fowl bedding materials, conventional paper-basedbedding frequently contains contaminants that are a result of poorquality old newspapers. Since the animals frequently ingest the bedding,some of these contaminants can cause illness and therefore growth issueswith the animals. Mold and bacteria are a significant problem withconventional wood shavings or sawdust. These also are supplied withwidely varying levels of moisture.

Conventional paper-based bedding has previously been supplied either aschips of paper or as fiber. These tend to not be as absorbent andcompact tightly minimizing the thermal advantages. Customers willendeavor to reconstitute or fluff up their bedding to allow it to dryand gain additional life from the bedding. Conventional paper-basedbedding is produced in a dry process using various shredders andhammer-mills, thus making the addition of additives that adequatelyadhere to the fibers difficult or inefficient.

Conventional paper-based bedding is produced using ONP and other commonrecycled paper based products. Conventional processes do not have thecapability of managing and therefore reducing the inorganic componentsof the raw material. Inorganic particles add to the dust level of thefinished product, add no absorption qualities and aid in the compactionissues inherent with paper-based bedding.

There are several purposes for providing animal and fowl bedding: animaland fowl bedding absorbs excess moisture from the droppings and drinkersand promotes drying by increasing the surface area of the house floor;animal and fowl bedding dilutes fecal material, thus reducing contactbetween birds and manure; and in the poultry industry, animal and fowlbedding insulates chicks from the cooling effects of the ground andprovides a protective cushion between the birds and the floor.

An effective bedding material must be absorbent, lightweight,inexpensive and non-toxic. Ideal materials will have high moistureabsorption and release qualities to minimize litter caking. In addition,a bedding material must be compatible as a fertilizer or soil amendmentor for incineration after it has served its purpose in the poultryhouse.

Excess moisture in the litter increases the incidence of breastblisters, skin burns, scabby areas, bruising, condemnations anddowngrades. The wetter the litter, the more likely it will promote theproliferation of pathogenic bacteria and molds. Wet litter is also theprimary cause of ammonia emissions, one of the most serious performanceand environmental factors affecting broiler production today.Controlling litter moisture is the most important step in avoidingammonia problems.

Conventional animal and fowl bedding products have significantdisadvantages, as Table I indicates:

TABLE I Advantages and Disadvantages of Various Animal and Fowl BeddingMaterials Pine shavings Preferred litter material but becoming limitedand sawdust in supply and expensive in areas. Hardwood shavings Oftenhigh in moisture and susceptible to and sawdust dangerous mold growth ifstored improperly prior to use. Pine or Used successfully but may causeincreased hardwood chips incidence of breast blisters if allowed tobecome too wet. Pine or Similar to chips or shavings in moisturehardwood bark absorption capacity. Medium-sized particles preferred.Rice hulls A good litter material where available at a competitiveprice. Young chicks may be prone to litter eating (not a seriousproblem). Peanut hulls An inexpensive litter material in peanut-producing areas. Tends to cake and crust but can be managed. Susceptibleto mold growth and increased incidence of aspergillosis. Some problemswith pesticides have been noted in the past. Sand Field trials showcomparable performance to pine shavings. Long-term reuse potential withde-caking. More difficult to maintain suitable floor temperatures duringcold weather brooding. Need ample time and ventilation prior to broodingto assure dryness. Crushed corn cobs Limited availability. May beassociated with increased breast blisters. Chopped straw, Considerabletendency toward caking. Mold hay or corn stover growth can also be adisadvantage. Processed paper Various forms of processed paper haveproven to be good litter material in research and commercial situations.Tendency to cake with increased particle size. Top dressing paper basewith shavings may minimize this problem.

Despite these known animal and fowl bedding products, and the increasingneed for a high quality, inexpensive and widely available product,limited commercial products or processes have been developed to meet theneeds of private and commercial animal owners for animal and fowlbedding. These needs include: (a) a higher degree of absorbency thansawdust, straw or wood shavings; (b) a higher degree of absorbency thanconventional paper-based bedding; (c) a consistently manufacturedproduct; (d) a uniform particle size and composition; (e) a product thatmaintains its uniform particle size and composition without severecompaction; (f) improved thermal qualities; and (g) relatively quickdecomposition following disposal. Furthermore, consumer and commercialusers of animal and fowl bedding would greatly appreciate animal andfowl bedding that is virtually free from contamination, can be custommanufactured to include performance enhancers, is delivered withconsistent moisture content levels, that can be purchased in packagesthat are relatively clean and easy to store, and which can be used forbiomass power generation in a manner that is safe for the environment.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a cellulosic thermal insulationcomposition is provided with selective inorganic contents resulting in aselective final product ash content. In another aspect of the presentinvention, a composition is provided that is produced in a wet pulpingprocess using non-traditional raw materials (such as beater dye,materials recycling facility (MRF) residual, fibers laminated withplastic and/or metal foil, pulp sludge, wet cellulosic fibers,industrial waste, mixed waste, post-consumer mixed recyclables, mixedoffice waste, post-consumer industrial fiber waste, and other commercialwaste).

In another aspect of the present invention, a system and a method areprovided for manufacturing commercially saleable cellulosic insulationfrom non-traditional raw materials (such as beater dye, MRF residual,fibers laminated with plastic and/or metal foil, pulp sludge, wetcellulosic fibers, industrial waste, mixed waste, post-consumer mixedrecyclables, mixed office waste, post-consumer industrial fiber waste,and other commercial waste) without utilizing a process to substantiallypre-separate and dispose of any contaminates.

In a further aspect of the present invention, a system and method areprovided to process raw materials containing cellulosic fibers with highlevels of inorganic chemicals such that the amount of inorganicmaterials contained in the processed material falls below a specific ashcontent that provides for a commercially saleable cellulosic insulation.

In a further aspect of the present invention, a method is provided forprocessing previously un-processable materials in a conventional hydropulper (such materials as beater dye, MRF residual, fibers laminatedwith plastic and/or metal foil, pulp sludge, wet cellulosic fibers,industrial waste, mixed waste, post-consumer mixed recyclables, mixedoffice waste, post-consumer industrial fiber waste, and other commercialwaste that are currently being sent to a landfill for disposal).

Still another aspect of the present invention is to provide a method forprocessing previously un-processable materials (such as beater dye, MRFresidual, fibers laminated with plastic and/or metal foil, pulp sludge,wet cellulosic fibers, industrial waste, mixed waste, post-consumermixed recyclables, mixed office waste, post-consumer industrial fiberwaste and other commercial waste that are currently being sent to alandfill for disposal) whereby the fiber recovery process releasesfines, clays, calcium carbonate, and other non-organic material into apulping fluid, which is then referred to as dirty water. The pulpingfluid is preferably further processed through one or more clarifierswith select solids separation reagents to selectively remove excessfines, clays, calcium carbonate, and other inorganic materials that aredetrimental to producing cellulosic insulation with a total ash contentequal to or less than 10%, that meets the commercial productrequirements listed herein.

Still another aspect of the present invention is to recover commerciallyviable compounds (such as aluminum hydroxide, magnesium hydroxide, andcalcium carbonate) in order to reduce the overall cost of the fiberrecovery process.

Preferably, a method according to one embodiment of the presentinvention processes commingled materials (such as beater dye, MRFresidual, fibers laminated with plastic and/or metal foil, pulp sludge,wet cellulosic fibers, industrial waste, mixed waste, post-consumermixed recyclables, mixed office waste, post-consumer industrial fiberwaste, and other commercial waste). These materials are first depositedinto a fiber recovery apparatus such as a tunnel washer or ahydro-pulper, where the commingled materials are washed in a pulpingfluid that includes water, fire retardant chemicals, dyes, insecticides,biocides, surfactants, decay inhibitors, and polymers. The disposedmaterials are preferably agitated in the first two zones of the fiberrecovery apparatus, so as to separate the cellulosic fibers from thenon-cellulosic material (which includes plastic, metal foil, and fillerssuch as calcium carbonate and clay, and other contaminates). Preferably,the cellulosic material and large containments are then transferred to athird fiber recovery apparatus where the cellulosic fibers are filteredout and away from the non-cellulosic fibers with the process liquor, forfurther processing. Preferably, the non-cellulosic materials are thenscooped out of the end of the third zone of the fiber recovery apparatusand disposed of. The dirtied pulping fluid is further processed throughone or more clarifiers with select solids separation reagents andpolymers to selectively remove fines, clays, calcium carbonate and othernon-organic material, and then returned to the pulping fluid that ispreferably in a closed loop system. The cellulosic fibers are preferablyfurther processed through a series of presses to remove excess water andpulping fluid, disc refiner(s) to fluff the fibers, a dryer(s), and apackaging machine.

Another aspect of the present invention is to provide a cellulosicthermal insulation which is formed from the materials through thepreferred wet pulping process described herein, with a inorganic ortotal ash content equal to or less than 10% including the fire retardantchemicals.

Accordingly, the above described disadvantages are overcome and a numberof advantages are realized by a first aspect of the present inventionwhich relates to a process for recovering organic cellulosic fibers fromlandfill materials such as post consumer, municipal and industrial wastematerials comprising: a. selectively introducing waste materialscontaining organic cellulosic fibers into a size reduction machine; b.conveying such pre-cleaned waste material to a tank, drum or tunnel typefiber recovery apparatus; and c. subjecting such waste material for aselected period of time to mechanical and fluid fiberization. The methodof first aspect of the present invention further comprises: d.introducing a pulping fluid containing chemicals to enhance the fiberseparation process; e. selectively treating the recovered fibers withrapidly penetrating flame retardants, insecticidal properties and decayinhibitors; f. selectively dyeing the separated fibers to selectedcolors; and, g. providing solids separation reagents to selectivelyremove contaminants in the pulping fluids. In the first aspect of thepresent invention, the pulping fluid is selectively heated to atemperature range between about 50° F. to about 200° F.

The method of first aspect of the present invention further comprises:h. cleaning the recovered fibers through screening and hydro-cleaningdevices to remove plastics and tramp metal; i. conveying the removedplastics and tramp metals to a waste disposal system consisting of areceiving tank and a sludge press; j. extracting a high percentage ofthe pulping fluid for further processing; k. subjecting the recoveredfibers to a mechanical disk refiner to control fiber length, fiberbundle separation and fiber surface properties; l. removing contaminantsconsisting of fillers, fines, coatings and other extraneous materialsthrough the use of one or more clarifiers with select solids separationreagents and polymers; m. extracting pulping fluids and water from therecovered fibers to formulate a cellulosic fiber wet lap of about 40% toabout 60% pulp solids content; n. fluffing the cellulosic fiber wet lapin a cake fluffer and a disk refiner; and o. drying the fluffed fibersin a flash or tunnel dryer; and p. conveying the dried fibers to apackaging or baling system.

According to the first aspect of the present invention, the step ofdrying comprises: drying the fluffed fibers at a temperature from about150° F. to about 700° F., thereby reducing bacteria content of therecovered fibers, and drying them to a uniform moisture content, andwherein the uniform moisture content is between about 10% and about 18%.According to the first aspect of the present invention, the dried fibershave a bulk density of between about 2 pounds per cubic foot to about 6pounds per cubic foot, and the dried fibers are used for animal and fowlbedding and have a higher degree of absorbency than sawdust, straw, woodshaving, or conventional paper-based bedding, and further wherein thedried fibers used for animal and fowl bedding are about six times moreabsorbent than sawdust, straw or wood shavings. Still further accordingto the first aspect of the present invention, the dried fibers used foranimal and fowl bedding are between about 18% to about 25% moreabsorbent than conventional paper-based bedding, and incur between about40% to about 50% less compaction than conventional paper-based animaland fowl bedding.

According to the first aspect of the present invention, the processfurther comprises: q. removing inorganic precipitated chemicals andcontaminants from the extracted pulping fluids; and r. recycling thepulping fluids back to the primary tank/drum/tunnel fiber recoveryapparatus. According to the first aspect of the present invention, theremoved inorganic precipitated chemicals and selected contaminantscomprise calcium hydroxide, calcium carbonate calcites, aluminumhydroxide, aluminum oxide, magnesium hydroxide and/or various otherminor hydroxides. Still further according to the first aspect of thepresent invention, the recovered organic cellulosic fibers comprise afinal total ash content equal to or less than about 10%. According tothe first aspect of the present invention, the recovered organiccellulosic fibers comprise a final total ash content of about 8.09%, andwherein the recovered organic cellulosic fibers comprise an averagefiber length greater than about 0.700 mm. According to the first aspectof the present invention, the recovered organic cellulosic fiberscomprise an average fiber length of about 0.780 mm.

A second aspect of the present invention is provided that relates to acellulosic insulating fiber product that is used for thermal insulationin applications ranging from about −50° F. to about +170° F., whereinthe composition of the fiber product has a bulk density of about 1.0pounds per cubic foot, to about 1.6 pounds per cubic foot, thecomposition of the fiber product is substantially free of dustparticles, and wherein the composition of the fiber product has a finaltotal ash content equal to or less than about 10%.

According to the second aspect of the present invention, the final totalash content is less than about 9%. According to the second aspect of thepresent invention, the final total ash content is about 8.09%, andwherein the fiber product is selectively dyed to provide brandidentification. According to the second aspect of the present invention,the fiber product is used as acoustical insulation, packaging materials,industrial thickeners or fillers to be combined with other products,hydro-mulch and other related uses.

According to a third aspect of the present invention, a cellulosicanimal and fowl bedding fiber product is provided that is used for theabsorption of excess moisture, fecal matter and thermal insulation inanimal applications, wherein the composition of the cellulosic animaland fowl bedding fiber product has a bulk density of about 2.0 poundsper cubic foot to about 6.0 pounds per cubic foot, the composition ofthe cellulosic animal and fowl bedding fiber product is substantiallyfree of dust particles, and wherein the composition of the cellulosicanimal and fowl bedding fiber product has a final total ash contentequal to or less than about 10%. According to the third aspect of thepresent invention, the ash content is less than about 9%. According tothe third aspect of the present invention, the ash content is about8.09%, and the fiber product is selectively dyed to provide brandidentification.

According to the third aspect of the present invention, the fiberproduct has a higher absorbency than wood shavings, sawdust or straw andconventional paper-based litter, and the fiber product reduces footsores in poultry products in comparison to wood based bedding. Stillfurther according to the third aspect of the present invention, fiberproduct is used for animal and fowl bedding and incurs between about 40%to about 50% less compaction than conventional paper-based animal andfowl bedding.

According to a fourth aspect of the present invention, a system forrecovering organic cellulosic fibers from landfill materials such aspost consumer, municipal and industrial waste materials is providedcomprising: a. means for selectively introducing waste materialscontaining organic cellulosic fibers into a size reduction machine; b.means for conveying such pre-cleaned waste material to a tank, drum ortunnel type fiber recovery apparatus; and c. means for subjecting suchwaste material for a selected period of time to mechanical and fluidfiberization. The system according to the fourth aspect of the presentinvention further comprises: d. means for introducing a pulping fluidcontaining chemicals to enhance the fiber separation process; e. meansfor selectively treating the recovered fibers with rapidly penetratingflame retardants, insecticidal properties and decay inhibitors; f. meansfor selectively dyeing the separated fibers to selected colors; and, g.means for providing solids separation reagents to selectively removecontaminants in the pulping fluids. According to the fourth aspect ofthe present invention, the pulping fluid is selectively heated to atemperature range between about 50° F. to about 200° F., and the systemfurther comprises: h. means for cleaning the recovered fibers throughscreening and hydro-cleaning devices to remove plastics and tramp metal;i. means for conveying the removed plastics and tramp metals to a wastedisposal system consisting of a receiving tank and a sludge press; andj. means for extracting a high percentage of the pulping fluid forfurther processing.

According to the fourth aspect of the present invention, the systemstill further comprises k. means for subjecting the recovered fibers toa mechanical disk refiner to control fiber length, fiber bundleseparation and fiber surface properties; l. means for removingcontaminants consisting of fillers, fines, coatings and other extraneousmaterials through the use of one or more clarifiers with select solidsseparation reagents and polymers; m. means for extracting pulping fluidsand water from the recovered fibers to formulate a cellulosic fiber wetlap of about 40% to about 60% pulp solids content; n. means for fluffingthe cellulosic fiber wet lap in a cake fluffer and a disk refiner; o.means for drying the fluffed fibers in a flash and/or tunnel dryer; andp. means for conveying the dried fibers to a packaging or baling system.According to the fourth aspect of the present invention, the means fordrying comprises: drying the fluffed fibers at a temperature above about150° F. to about 700° F., thereby reducing bacteria in the fluffedrecovered fibers.

According to the fourth aspect of the present invention, the means fordrying comprises: drying the fluffed fibers at a temperature above about300° F., thereby reducing bacteria in the fluffed recovered fibers, anddrying them to a uniform moisture content, and wherein the moisturecontent is between about 10% and about 18%.

According to the fourth aspect of the present invention, the systemfurther comprises q. means for removing inorganic precipitated chemicalsand contaminants from the extracted pulping fluids; and r. means forrecycling the pulping fluids back to the primary tank/drum/tunnel fiberrecovery apparatus. According to the fourth aspect of the presentinvention, the removed inorganic precipitated chemicals and selectedcontaminants comprise calcium hydroxide, calcium carbonate calcites,aluminum hydroxide, aluminum oxide, magnesium hydroxide and/or variousother minor hydroxides, and wherein the recovered organic cellulosicfibers comprise a final total ash content equal to or less than about10%.

According to the fourth aspect of the present invention, the recoveredorganic cellulosic fibers comprise an average fiber length greater thanabout 0.700 mm. According to the fourth aspect of the present invention,the recovered organic cellulosic fibers comprise an average fiber lengthgreater than about 0.780 mm.

According to a fifth aspect of the present invention, a method forrecovering cellulosic fibers from mixed trash is provided comprising: a.loading waste containing cellulosic fibers and other non-organicmaterials into a sorting apparatus to produce a combination of short andlong fiber feedstock; b. blending the sorted trash to maintain ratio ofabout 50% to about 90% short fiber feedstock and about 10% to about 50%long fiber feedstock; c. shredding the blended sorted fiber feedstock;d. weighing the shredded fiber feedstock into load sizes of about 100 toabout 300 lbs; e. pulping the weighed fiber feedstock into cellulosicfibers and a first through fourth group of select waste materials withpulping fluids in a fiber extractor recovery apparatus therebyimpregnating the cellulosic fibers with the pulping fluids: f. drainingthe cellulosic fibers from the extractor fiber recovery apparatus into ahydro-cleaner; g. de-watering the impregnated cellulosic fibers in thehydro-cleaner to reduce the amount of pulping fluid in the impregnatedcellulosic fibers, and extracting a portion of the second group ofselect waste materials; h. depositing the extracted portion of secondgroup of select waste materials into a landfill; i. fluffing thede-watered cellulosic fibers in a first disk refiner; j. thickening thefluffed cellulosic fibers in a thickener and extracting pulping fluidfor re-use in the fiber extractor recovery apparatus; k. storing thethickened cellulosic fibers in a stock chest apparatus; l. extractingpulping fluid from the thickened cellulosic fibers in a pulping fluidextractor; m. impregnating additional chemicals comprising fireretardant chemicals, dyes, insecticides, and/or biocides, such that thefinal cellulosic fiber product comprises a flame retardant loading ofabout 6%; n. extracting excess pulping fluid from the thickenedcellulosic fibers in a pulp press thereby producing partially driedthickened cellulosic fibers; o. fluffing the partially dried thickenedcellulosic fibers in a fluffer apparatus that reduces a density of thecellulosic fibers from a first range of about 6 to about 10 lbs percubic foot to a second density range from about 2 to about 6 lbs percubic foot, with a post fluffing moisture content of about 40% to about60%; p. additionally fluffing the cellulosic fibers in a second diskrefiner at a temperature between about 150° F. and about 700° F.; q.drying the cellulosic fibers in a dryer to further reduce the moisturecontent to about 10% to about 18%; and s. packaging and/or baling thedried cellulosic fibers.

According to the fifth aspect of the present invention, the step ofpulping comprises: i. rotating and agitating the shredded fiberfeedstock in a plurality of fiber recovery apparatuses into cellulosicfibers and first through fourth groups of select waste materials, eachof the fiber recovery apparatuses containing pulping fluid, wherein thepulping fluid comprises a combination of water, fire retardantchemicals, biocides, dyes, insecticides and surfactants; ii.impregnating the cellulosic fibers and the first through fourth selectwaste materials with fire resistant chemicals, dyes, chemicalinsecticides, and/or biocides; iii. separating the impregnatedcellulosic fibers from the first group of select waste materials thatare not utilized or desired in separator fiber recovery apparatuses; iv.extracting the first group of select waste materials dissolved withinthe pulping fluid from the cellulosic fibers in a dirty water tank, DAFcontaminant separator, waste tank, sludge press and then depositing thefirst group of select waste materials into a landfill; v. separating theimpregnated cellulosic fibers from the second group of select wastematerials in an extractor fiber recovery apparatus; and vi. extractingthe second group of select waste materials from the impregnatedcellulosic fibers.

According to the fifth aspect of the present invention, the methodfurther comprises t. transferring pulping fluid extracted from thepulping fluid extractor and pulp press to a dirty water storage chest toextract additional inorganic compounds such as calcium carbonate,aluminum and magnesium hydroxide; u. adding one or more acids to thewater and pulping fluid stored in the dirty water storage chest to lowerthe pH of the pulping fluid to a range of about 4.0 to about 5.0; v.mixing the pulping fluids in a first precipitator with one or morealkaline agents to increase the pH of the pulping fluid to a range ofabout 4.5 to about 6.0 to cause precipitation of aluminum and magnesiumhydroxide byproducts; w. centrifuging the mixture of pulping fluids andprecipitated aluminum and magnesium hydroxide byproducts in a firstcentrifuge to separate and discard the aluminum and magnesium hydroxidebyproducts; x. adding carbon dioxide to the first centrifuged pulpingfluids; y. mixing the pulping fluids in a second precipitator with oneor more additional alkaline agents to increase the pH of the carbonatedpulping fluids to a range of about 11.5 to about 12.8 or to a pH pointwherein calcium carbonate precipitates from the carbonated pulpingfluids; z. centrifuging the mixture of carbonated pulping fluids andprecipitated calcium carbonate byproducts in a second centrifuge toseparate and discard the calcium carbonate byproducts, thereby producingtreated white water for use in the recovery process; and aa. storing thetreated white water in storage tanks for use in the recover process andapparatus.

According to the fifth aspect of the present invention, step ofadditionally fluffing the cellulosic fibers in a second disk refiner isomitted, and the step of drying includes drying the cellulosic fibers ata temperature between about 250° F. and 350° F., thereby producinganimal and fowl bedding product.

According to a sixth aspect of the present invention, a system forrecovering organic cellulosic fibers from landfill materials is providedcomprising: a. a stock preparation apparatus configured to prepare asuitable combination of short fiber and long fiber feedstock for use inthe cellulosic fiber recovery system from landfill materials and furtherconfigured to mix the short fiber and long fiber feedstock with apulping fluid thereby initially separating the short fibers and longfibers from first through fourth groups of select waste materials, andto further process the first group of select waste materials; b. a stockextraction apparatus configured to further mix the separated short andlong fiber feedstock with the pulping fluid, and to extract a secondgroup of select waste materials thereby producing a thickened slurry ofcellulosic fibers from the combination of short and long fiber feedstockthat is substantially free from the second group of select wastematerials; and c. a pulp drying and packaging apparatus configured toextract pulping fluid from the thickened slurry of cellulosic fibers,and which is further configured to separate third and fourth groups ofselect waste materials from the pulping fluid and to fluff, dry, andbale the thickened slurry of cellulosic fibers as recovered organiccellulosic fibers with a moisture content of about 10% to about 18%.

According to the sixth aspect of the present invention, the first groupof select waste materials comprises fillers, coatings, fines, clays,among other non-organic materials, the second group of select wastematerials comprises plastics, metals, glass, among others, and the thirdgroup of select waste materials comprises calcium carbonate, amongothers. According to the sixth aspect of the present invention, thefourth group of select waste materials comprises aluminum and magnesiumhydroxides, among others, and wherein the stock preparation apparatuscomprises: a. a trash sorting apparatus configured to sort gross trashinto a first group of trash comprising cellulosic fibers, and a secondgroup of trash that is substantially free of cellulosic fibers; b. afiber blending apparatus configured to selectively and mechanicallyblend the first group of trash comprising cellulosic fibers such that aratio of about 50% to about 90% of short cellulosic fibers and about 10%to about 90% long cellulosic fibers is maintained in the recoverysystem; c. a shredder apparatus configured to continuously shred theselectively maintained short and long cellulosic fibers into smallerpieces; d. a weigh feeder configured to continuously measure theshredded short and long cellulosic fibers into substantially equivalentloads of about 100 lbs to about 300 lbs per load; e. one or moredrums/tunnel pulpers configured to substantially continuously mixpulping fluids with the shredded short and long cellulosic fibers suchthat separation of short and long cellulosic fibers from first throughfourth groups of select waste materials occurs, and treatment of theshort and long cellulosic fibers with the pulping fluid occurs; and f. achemical dissolver configured to produce the pulping fluids from acombination of water, and rapidly penetrating surfactants, dyes,insecticides, biocides, and/or flame retardants.

According to the sixth aspect of the present invention, the shortcellulosic fiber comprises fibers of a first length from about 0.5 mm toabout 0.7 mm, and the long cellulosic fiber comprises fibers of a secondlength from about 0.7 mm to about 0.9 mm.

According to the sixth aspect of the present invention, the one or moredrums/tunnels are further configured to rotate at substantially equalintervals, and then reverse rotation for a second interval, in the casethere are more than one drum/tunnel, in order to transfer the mixture ofpulping fluids and shredded short and long cellulosic fibers from afirst to a subsequent drum/tunnel, and from the subsequent drum/tunnelto additional subsequent drum/tunnels should there be such additionalsubsequent drum/tunnels; and wherein the one or more drum/tunnels arefurther configured to transfer the mixture of pulping fluids, shreddedshort and long cellulosic fibers into an additional processing stageduring the reverse rotation interval.

According to the sixth aspect of the present invention, the fireretardants comprise those fire retardants that when absorbed by theshort and long cellulosic fibers meet federal requirements STM C-739,C-1149, C-1497, and CPSC 16 C.F.R. §§208, 1404.

According to the sixth aspect of the present invention, the stockextraction apparatus comprises: i. one or more additional drums/tunnelpulpers configured to further substantially continuously mix pulpingfluids with the shredded short and long cellulosic fibers such thatseparation of short and long cellulosic fibers further occurs from afirst and second group of select waste material, and continuoustreatment of the short and long cellulosic fibers with the pulping fluidoccurs producing a cellulosic fiber slurry, and further wherein thesecond group of select waste materials is removed from the one or moreadditional drums/tunnel pulpers, and further wherein the cellulosicfiber slurry is also transferred out of the one or more additionaldrums/tunnel pulpers; ii. an extractor configured to hold thetransferred cellulosic fiber slurry; iii. a hydrocleaner configured toextract still additional second group of select waste materials from thecellulosic fiber slurry; iv. a disk refiner configured to fluff thecellulosic fiber slurry; v. a thickener configured to remove waterand/or additional liquids from the fluffed cellulosic fiber slurry suchthat the percentage of cellulosic fibers with the fluffed cellulosicfiber slurry increases from a first range of about 1.5% to about 2% to asecond range of about 3.0% to about 4.5%; and vi. a plurality of whitewater holding tanks configured to hold the water and other liquidsremoved by the thickener.

According to the sixth aspect of the present invention, the pulp dryingand packaging apparatus comprises: i. a pulping fluid extractorconfigured to extract additional pulping fluid from the thickenedcellulosic fiber slurry; ii. an additional chemical dissolver tank toproduce an optional fire retardant spray comprising fire retardantchemicals, dyes, insecticides and/or biocides, wherein the optional fireretardant spray can be applied to the thickened fiber cellulosic slurry;iii. a pulp press configured to extract additional water and/or otherliquids such that the thickened fiber cellulosic slurry is about 40% toabout 60% solids, thereby producing cellulosic fiber wet lap; iv. afluffer configured to fluff the cellulosic fiber wet lap into a fluffedcellulosic fiber wet lap; v. a disk refiner configured to additionallyfluff the fluffed cellulosic fiber wet lap; vi. a flash/tunnel dryerconfigured to dry the fluffed cellulosic fiber wet lap at a temperaturebetween about 150° F. and about 700° F., thereby reducing a moisturecontent to a range of about 10% to about 18%; and vii. a packaging orbailing apparatus configured to packagee or bail the substantially dryfluffed cellulosic fiber wet lap.

According to the sixth aspect of the present invention, the systemfurther comprises a water treatment apparatus configured to recoverpulping fluid at various points in the recovery process, separate thethird and fourth group of select waste materials from the pulping fluidthereby creating treated white water which can then be returned to therecover system for continuous recovery of organic cellulosic fibers fromlandfill materials.

According to the sixth aspect of the present invention, the watertreatment apparatus comprises: a. an acid supply tank configured tostore a supply of one or more acids, comprising sulfuric acid,phosphoric acid, acidic acid, among others; b. a dirty water storagetank configured to receive pulping fluids removed from the fluffedcellulosic fiber slurry by the thickener and further configured to addone or more of the acids stored in the acid supply tank such that a pHlevel of the pulping fluids is reduced to a range of about 4.0 to about5.0 so as to dissolve one or more organic compounds comprising calciumcarbonate, aluminum hydroxide, magnesium hydroxide, among others; c. afirst alkaline agent holding tank configured to store one or more agentscomprising sodium tetraborate, sodium borates, calcium borates, ammoniumhydroxide, anhydrous ammonia, lime, and/or soda ash, among others; d. afirst precipitator configured to the receive water and/or additionalliquids from the dirty water storage tank, and further configured to addone or more of the agents stored in the first alkaline agent storagetank such that a pH level of the received pulping fluids is increased toa range of about 4.5 to about 6.0 so as to cause precipitation ofaluminum and magnesium hydroxide byproducts; e. a first centrifugeconfigured to received the pulping fluids from the first precipitator,and further configured to centrifuge the first precipitated pulpingfluids to separate and collect the aluminum and magnesium hydroxidebyproducts; f. a carbonator configured to receive the pulping fluidsfrom the first centrifuge, and further configured to add carbon dioxideto the pulping fluids; g. a second alkaline agent holding tankconfigured to store one or more agents comprising sodium tetraborate,sodium borates, calcium borates, ammonium hydroxide, anhydrous ammonia,lime, and/or soda ash, among others; h. a second precipitator configuredto receive the pulping fluids from the carbonator, and furtherconfigured to add one or more of the agents stored in the secondalkaline agent storage tank such that a pH level of the received pulpingfluids is increased to a range of about 11.5 to about 12.0, or to suchpH level so as to cause precipitation of calcium carbonate; i. a secondcentrifuge configured to received the pulping fluids from the secondprecipitator, and further configured to centrifuge the secondprecipitated pulping fluids to separate and collect the calciumcarbonate; and j. a treated white water storage tank configured to storeand transfer the treated white water now substantially free of calciumcarbonate, and aluminum and magnesium hydroxide byproducts and which hasa pH level in the range of about 11.5 to about 12.0. According to thesixth aspect of the present invention, the flash/tunnel dryer isconfigured to dry the fluffed cellulosic fiber wet lap at a temperaturebetween about 250° F. and about 350° F.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantageous structure and/or methods according to the presentinvention will be more easily understood from the following detaileddescription of the preferred embodiments and the appended drawings, asfollows.

FIG. 1 is a schematic diagram of the structure and method of the stockpreparation zone, the stock extraction zone, and the process heatelement according to a preferred embodiment of the present invention.

FIG. 2 is a schematic diagram of the structure and method of the watertreatment zone and the pulp drying and packaging zone according to apreferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY EMBODIMENTSIntroduction

A notable aspect of the present invention has been the discovery thatthe increasing quantities of inorganic compounds found in the varioussolid and fiber-containing household and industrial waste materialsadversely affect the physical properties of cellulosic thermalinsulation. The physical properties that primarily affect thermalinsulation in a substantially negative way are bulk density, thermalresistance, and nuisance dust content. All three of these properties areimportant in manufacturing an effective thermal insulation product.

Thermal resistance, or R-value, measures cellulose insulation'seffectiveness. High quality insulation products are more effectivebecause of their high R-values. Creating air spaces around the fibers,the natural fiber wall of the cells, and the air cells that naturallyexist within the fibers themselves, maximize R-value in celluloseinsulation. R-value degrades with the addition of inorganic particles,including fire retardant chemicals that tend to be conductors of thermalenergy rather than insulators. Therefore, minimizing the amount ofinorganic particles within cellulose insulation will increase itsthermal performance. Inorganic particles are collectively referred to as“ash”.

There is a direct correlation between inorganic levels in the finishedproduct and the product's density and dust level. R-value is a functionof a product's design density as well. As cellulose insulation densityincreases, the R-value decreases. The optimal density for celluloseinsulation that maximizes the R-value is a range between about 1.3 andabout 1.7 pounds per cubic foot. Inorganic particles that are notremoved increase a product's density, effecting R-value (making itlower) and hence the coverage of the finished product.

An attribute of quality that is normally not tested by manufacturers,but which is a significant issue for customers (installers), is thelevel of dust that the product emits while installing it. High dustlevels during installation is extremely uncomfortable for the installer,makes it difficult for them to see their application and createschallenges for living environments within a home. A high dust levelindicates high levels of inorganic components that free themselvesduring the installation of the product.

Cellulosic insulation manufactured according to the exemplaryembodiments of the present invention described herein containsignificantly reduces levels of ash than other manufacturer's cellulosicinsulation product. Various competitor's ash content are, an average,about 15.59%, whereas the ash content of the cellulosic insulationmanufactured according to the preferred embodiments of the presentinvention is about 8.09%, a decrease of about 100%.

TABLE II Comparison of Ash Levels of Insulation Products ManufacturedAccording to an Embodiment of the Present Invention, and Other MaterialsMaterial Avg. % Ash Cellulosic Fiber Insulation Manufactured According8.09 to an Embodiment of the Present Invention Competitor Insulation15.59 Sludge 16.67 Foil Laminates 14.17 White Fiber 7.85

As can be seen from Table II, which shows the ash content of severaldifferent materials, cellulosic fiber insulation products manufacturedusing the system and method according to the different embodiments ofthe present invention achieve significantly lower ash contents. Thecellulosic fiber insulation product manufactured according to anembodiment of the present invention has an ash content on average ofabout 8.09%. A competitor's fiber insulation product has an ash contenton average of about 15.59%. The ash content of sludge, which is thewaste material created by the system and method according to anembodiment of the present invention that is sent to the landfill (seeFIG. 1, output of sludge press 21, and landfill 23), has an ash contenton average of about 16.67%. Thus a significant amount of ash is removedduring the manufacturing process. The ash content of foil laminates,which are raw materials going into the system (see feedstock 1 inFIG. 1) is, on average, about 14.17%. This shows that a significantamount of ash is removed from the raw waste materials during the processaccording to an embodiment of the present invention. Finally, only whenvery select raw materials are tested, in this case white fiber, is theash content lower at about 7.85% on average. In the aforementioned testanalysis, golf ball boxes were used as a source of white fiber. Evenwhen starting with low-ash content raw materials (such as golf ballboxes), because addition of the fire retardant chemicals adds ash,reduction of total ash content remains an important feature of themethod and system according to an embodiment of the present invention.

Managing the ash content in the pulping process is a significant issuethat affects product quality and usability (density and dust). As theash content values discussed above indicate, the reduction achieved bycompetitors' products is minimal since most of the fillers (ash) iscontained within the insulation pieces and holds the fibers together.Therefore, minimizing the ash content of the fiber insulating product isvery important, otherwise an extremely dusty product with high densitylevels will be produced.

Thus, as noted above, the ash content of the products produced using thesystems and methods described herein is significant. The various rawmaterials processed by the system (e.g., post consumer, municipal andindustrial waster materials) can have residual ash content as high as50%, and unless the ash is significantly reduced, there is a negativeimpact on further processing, such as chemical addition, dryingcapability, speed of drying, temperature requirements, fiber sizereduction, product density and packaging. The process described hereinfurther reduces the ash to a level at or below 10% in order to improvevarious chemical additions, decrease drying temperature and time andimprove fiber sixe reduction and consistency of the finished products.

Further, another attribute that determines the effectiveness of thecellulosic insulation product is fiber length, and thus overall densityof the product. Longer fibers will improve (lower) a product's densityand by maintaining fiber structure, fewer fractured or short fibers areevident that could become part of the dust level in the finishedproduct. As Table III below indicates, the system and method of pulpingfibers according to the preferred embodiments of the present inventionproduce, on average, longer fibers than competitors' products as aresult, in part, through the pulping of the cellulosic fibers throughthe disk refiner among other steps and apparatus of the presentinvention. Competitors generally use dry processing, and as a result,their average fiber lengths are, an average, about 0.521 mm. The systemand method for pulping fibers according to the preferred embodiments ofthe present invention produces fibers on average of about 0.781 mm, anincrease, on average, of about 14% in length.

TABLE III Comparison of Fiber Length and Width of Insulation ProductsManufactured According to an Embodiment of the Present Invention, andOther Materials Average Length (ii) Material (mm) Cellulosic FiberInsulation Product 0.781 Manufactured According to an Embodiment of thePresent Invention Competitor Insulation 0.685 Sludge 0.666 FoilLaminates 0.689 White Fiber 0.849

Table III illustrates the results of testing of average lengths offibers of the cellulosic fiber insulation product as manufacturedaccording to an embodiment of the present invention versus othermaterials as discussed and shown in Table II. The increase in length ofthe product as manufactured according to an embodiment of the presentinvention versus that of the competitor results in an optimization ofthe density of the cellulosic fiber insulation product. Again, as withTable II, it is only when a material is handpicked to have optimallength properties (the white fiber material, i.e., golf ball boxes) doesthe length characteristics exceed that of the product as manufacturedaccording to an embodiment of the present invention that is made from anassortment of waste materials.

It has been further discovered that these inorganic compounds cannot beremoved from the waste feedstock using conventional dry processfiberization equipment due to the inorganic compounds being an integraland impregnated part of the fiber structure. Such compounds are removedby dissolving these compounds and then precipitating them from theliquid pulping fluids. The present invention uses a wet pulping processutilizing a fiber recovery apparatus to recover cellulosic fibers fromlandfill materials, and to manufacture a composition of cellulosicinsulation with low ash content with specific performance andcomposition characteristics. For example, the cellulosic insulationcomposition according to the present invention may comprise cellulosicfibers impregnated with liquid flame retardants, dyes, insecticides,decay inhibitors, and/or biocides. Note that fiber pulp is the endresult of the process machine. The present invention does not propose topulp the fiber, but rather pulp the feedstock.

As a brief overview, dry or wet waste containing cellulosic fibers andother non-organic materials (such as plastics, metal, clay, and calciumcarbonate) is preferably loaded into a fiber recovery apparatus and,while being agitated, is washed in water, surfactants, decay inhibitors,and polymers, and then is impregnated with fire retardant chemicals,dyes, insecticides, and/or biocides. During pulping, the cellulosicfibers become separated from select materials that are not utilized ordesired in the final product. The cellulosic fibers are drained out ofthe fiber recovery apparatus with the pulping fluid described herein,leaving the select non-cellulosic materials (i) in the fiber recoveryapparatus for disposal or (ii) in the pulping fluid, where additionalinorganic materials are precipitated and recovered out of the pulpingfluid. The cellulosic fibers are then transferred into a series ofprocess steps including a dewatering press to reduce the amount of waterin the cellulosic fibers, then fluffed, dried, and packaged.

For the purpose of this discussion, and as shown in the drawings,process liquor (or pulping fluid as it hereinafter will be referred to)is defined as a combination of water, fire retardant chemicals,biocides, insecticides, dyes, and surfactants. Pulping fluid is thefluid that aids in pulping and flocculation of the commingled wasteaccording to an embodiment of the present invention. As discussedherein, the pulping fluid includes chemical additives that enhance thefiber separation process. Importantly, waste solubilized organics arenon-desirable for the processes described herein, and therefore areflushed out as part of such processes.

Because the system and process described herein is designed to operatecontinuously, in order to increase efficiency and hence its economicperformance, the fluids used throughout the system will be continuouslychanging in terms of chemical composition and contaminants, as those ofordinary skill in the art can appreciate. However, in order tofacilitate an understanding of the system and method of the embodimentsof the present invention, the liquids that are utilized within can bedefined as follows: For the purpose of this discussion, and as shown inthe drawings, pulping fluid 47 is defined as a combination of water,fire retardant chemicals, biocides, insecticides, dyes, and surfactants.Process liquor, or pulping fluid 47, is the fluid that aids in pulpingand flocculation of the commingled waste according to an embodiment ofthe present invention. Pulping fluid 47 is the state of the fluid at thepoint of start up, when all the storage tanks and cells are filled withthe fluid to aid in de-pulping and flocculation. Pulping fluid 47 is thefluid leaves chemical dissolver tank 25 as shown in FIG. 1. Pulpingfluid 47, as described in greater detail below, is periodicallywithdrawn from the system at various points, and can be cleaned and/orrefined to become treated white water 51 that is in a state thatapproximates that of the original pulping fluid 47. As such, pulpingfluid 47 can have different levels and types of contaminants atdifferent points in the system and process according to the embodimentsof the present invention.

Pulping fluid 47 is inserted into Zone 1 of apparatus 6 from chemicaldissolver tank 25. Pulping fluid 47 is mixture of water, surfactants,insecticides, biocides, dyes and fire retardant chemicals. As soon aspulping fluid 47 starts mixing with the landfill waste it becomes dirty.Dirty water 48 is extracted from Zone 2 of apparatus 7. Dirty water 48is the most contaminated fluid within the system. The liquid that iscarried into Zone 3 of apparatus 8 is cleaner than dirty water 48 and iscalled white water 49. White water 49 is substantially free of solids(fillers, contaminants and coatings; which is what makes dirty waterdirty).

A portion of dirty water 49 is returned to fiber recovery apparatuses 6,7 and 8, untreated, and not cleaned at all. Most of dirty water 48,however, is sent to dirty water tank 22. Dirty water 48 is then sent toDAF containment separator 15; its output is untreated white water 50(meaning it is cleaner (no solids) than dirty water 48, but containscalcium carbonate, and aluminum and magnesium hydroxides). Untreatedwhite water 50 is stored (tanks 16, 17 and 18) and is added to dirtywater 48 that is taken from Zone 2.

White water 49 is extracted from thickener 12, and is immediatelyrecycled back to Zone 3, after being combined with untreated white water50 and treated white water 51. Some of white water 49—or pulping fluidwith containments (CaCO₃ aluminum and magnesium hydroxide by products)is retained by the fibers. In pulping fluid extractor 27, untreatedwhite water 50 is extracted from the fibers. While untreated white water50 contains calcium carbonates, and aluminum and magnesium hydroxides,it can be immediately re-used, because it has the chemicals needed bythe system (fire retardants, surfactants, biocides, insecticides, dyes,among others), and is substantially free of solid contaminants. Thebalance of untreated white water 50 is sent to the water treatment zone(See FIG. 2) to remove the calcium carbonate and aluminum and magnesiumhydroxides, the process of which is described in greater detail below.

Once the calcium carbonates and aluminum and magnesium hydroxides areremoved from untreated white water 50, the cleaned liquid is referred toas treated alkaline white water 51. Therefore, in terms of “cleanliness”the following is a list of the fluids used in the system and methodaccording to an embodiment of the present invention from cleanliest todirtiest: pulping fluid 47; treated alkaline white water 51; white water49; untreated white water 50; and dirty water 48.

Of course, as those of ordinary skill in the art of the presentinvention can appreciate, there is no set chemical/solid compositionthat completely defines the differences between pulping fluid 47, dirtywater 48, white water 49, untreated white water 50, or treated whitewater 51, and as such the definitions are not intended and should not beconstrued to limit the scope of the exemplary embodiments of the presentinvention, but are merely intended to be used as an aid for the readerto understand the processes and systems described herein.

As noted above, the residual pulping fluid is thus subjected to stagesof separation and cleaning in order to condition the pulping fluid forreuse as a pulping medium. Importantly, the specific inorganicprecipitated chemicals withdrawn from the fiber waste stream in order torecycle the pulping fluids back to the fiber recovery apparatus, if notremoved, would continue to build up and eventually impede theeffectiveness of future pulped fiber purity.

The system and method of the present invention involves the use ofdisposed products that contain cellulosic fibers (such as beater dye,MRF residual, fibers laminated with plastic and/or metal foil, pulpsludge, wet cellulosic fibers, industrial waste, mixed waste,post-consumer mixed recyclables, mixed office waste, post-consumerindustrial fiber waste, and other commercial waste) to preferablymanufacture cellulosic insulation with certain characteristics(including a total ash content equal to or less than about 10%). Thesedisposed products are currently sent to a landfill because they aretypically unsuitable to be processed into other commodities or products,and typically have an ash content of over about 15%.

The system and method described herein are able to produce cellulosicfibers while using a mixed variety of raw waste paper materials as thefeed stock, thus significantly improving upon the ability of othermethods that seek to process paper stock limited to, for example, oldnewspapers. Fibers recovered from such mixed trash can be of variedphysical characteristics and composition, particularly as compared tothose generated from a single source such as old newspaper. As describedherein, processing of such mixed trash requires a unique processcapability, additives, and drying technology in order to produce areasonably consistent product. Different fibers can have differentabsorbency rates and capability and, therefore, have differing dryingcharacteristics as well as differing capability to accept additives,such as dyes, insecticidal compositions, flame retardants, and decayinhibitors.

Advantageously, the method disclosed in the application does not requirepre-conditioning of any of the landfill materials in order to accomplishbiomass separation. Thus, size reduction of such materials is performedprior to the fibers being introduced to the pulping fluid, and aretherefore not solubilized and are at 80% to 90% solids. By so avoidingpre-conditioning of the landfill waste materials, the structuralintegrity of the cellulosic fibers in those materials is maintained.Rather, prior to the addition of any water, pulping fluid or pulpingactivity, the raw, mixed trash is subjected to a dry sorting process, adry blending process in which the sorted trash is blended to provide aparticularly desirable ratio of short to long cellulose fibers, and drymechanical shredding to alter the particle size of the materials whilemaintaining desirable fiber length, and thereafter pulping the fiberswith pulping fluid having chemical additives that are able to cover andimpregnate the cellulosic fibers.

The Structure and Process of the Preferred Embodiments

In FIGS. 1 and 2, there is shown a schematic view of the structure andprocess in accordance with the preferred embodiment. The system includesa manual trash-sorting station 2, a fiber blending chamber (blendingchamber) 3, a shredder 4, a weigh feeder 5, multiple zone fiber recoveryapparatuses 6, 7, and 8, a hydro-cleaner 10, a disk refiner 11, adissolved air flotation (DAF) contaminant separator or water clarifier(water clarifier) 15, a pulp slurry thickener 12, pulping fluidextractor (otherwise known as pulp dewatering presses) 27 and pulp press28, a pulp fluffer 29, a disk refiner 30, a flash/tunnel dryer (dryer)31, and a packaging or baling (packaging) system 32, among othercomponents.

Various waste materials 1 containing cellulosic fibers are sorted ofgross trash (out throws) in the manual trash-sorting station 2, thenthey are selectively and mechanically blended in a chamber 3 bymaintaining a preferred ratio of about 50% to about 90% short fiberfeedstock and about 10% to about 50% long fiber feedstock, and thenconveyed to a shredder 4 as manufactured by Saturn (model #Z2A) wherethe material is reduced in size. According to an exemplary embodiment ofthe present invention, short fibers are those fibers whose averagelength ranges from about 0.5 mm to about 0.7 mm, and long fibers arethose fibers whose average length ranges from about 0.7 mm to about 0.9mm. An example of cellulosic fibers that can be input to the systemaccording to an embodiment of the present invention that are shortfibers is the Foil laminates material described above, with an averagelength of about 0.689 mm. An example of cellulosic fibers that can beinput to the system according to an embodiment of the present inventionthat are long fibers is the white fiber material described above, withan average length of about 0.849 mm. The material continues to a weighfeeder 5 as manufactured by Ronan (model X96S) to measure load sizes ofabout 100 lbs to about 300 lbs, depending on the size of the fiberrecovery apparatuses 6, 7 and 8, and on automatic un-pulped materialfeedback from points later in the system.

One type of fiber recovery apparatus 6, 7, and 8 is a model #76039P4FContinuous Batch Tunnel Washer manufactured by Pellerin MilnorCorporation of Kenner, La., U.S.A. that is typically used for thewashing of textile goods (such as clothes) and has perforated drumsrotatable within multiple end-to-end compartments, or chambers, asdescribed herein. Continual processing of the waste through the systemprovides an efficient means for separating the cellulosic fibers fromvarious contaminants. Additionally, a continuous batch system results inan equilibrium of the chemical and other conditions within the apparatusto be established as the waste is processed due to the continuousrecirculation of the pulping fluids. Other pulping systems (such asdrum, tank or tunnel type pulping machines) may be used as fiberrecovery apparatus 6, 7 or 8, that provide various levels of fiberseparation from undesirable contaminates. Of course, the fiber recoveryapparatus may comprise a single apparatus 6, two apparatuses, threeapparatuses (as shown in FIG. 1), or more sections, as desired. Thefirst and second zones of apparatus 6 and apparatus 7 in the fiberrecovery apparatus are substantially similar to each other. One or moreof these apparatuses may include steam injection. Preferably, theprocess heat and steam are provided by a 143 Hp boiler, fed with naturalgas and capable of generating 50 Therms/hr. 47, as manufactured byWilliams Davis Boiler, Inc.

In more detail, approximately equal volumes or loads of waste material(from about 100 lbs to about 300 lbs) are loaded into the first chamberof the first zone of the fiber recovery apparatus 6 (preferablycomprising nine cells). As each load of waste is transferred from thefirst chamber (or cell) into the second chamber (or cell) of the firstapparatus 6, a new load of waste replaces it so that a steady stream ofwaste is continuously processed in the system. This waste continuesthrough the remaining chambers (or cells) of the fiber recoveryapparatuses 6, 7, and 8.

The multiple chambers (or cells) in each of apparatus 6, 7 and 8 arerotated for predetermined, essentially equal intervals e.g., about 20minutes. At the end of each interval, a predetermined sequence ofreverse rotation is initiated so as to transfer the batch in the chamberto a succeeding chamber. At the same time, the batch in the last chamberof apparatus 6 is transferred to the first chamber of apparatus 7 andthe last chamber of apparatus 7 transfers the batch into the firstchamber of apparatus 8. The fiber recovery apparatuses 6, 7 and 8 uses acontinuous flow of pulping fluid 47 that includes water, fire retardantchemicals, dyes, insecticides, biocides and surfactants that flowsthrough the fiber recovery apparatus. The composition of pulping fluid47 may consist of the following ingredients depending on the type offinished product that is being manufactured:

TABLE IV Pulping Fluid Composition PERCENTAGE RANGE (all ranges fromabout a first percentage INGREDIENTS to about a second percentage) Water80.0 to 95.0% w/v Flame Retardant's 0.5 to 20.0% w/v Surfactants 0.001to 2.0% w/v Boron Insecticides 0.12 to 3.0% w/v Biocides 0.001 to 2.0%w/v Dyes 0.05 to 2.0% w/v The flame retardants comprise about 40% toabout 60% ammonium sulfate (NH₄) 2SO₄ and from about 40% to about 60%boric acid H₃BO₃. Alternatively, a product can also be used thatincludes no ammonium sulfate as a fire retardant and 100% boric acid.

Pulping fluid 47 is preferably maintained at a temperature of at least120° F. to insure that the chemicals added to pulping fluid 47 remain insolution, and to increase the pulping activity within the chambers.According to an alternative embodiment of the present invention, pulpingfluid 47 can work properly at temperatures that range from about 50° F.,to about 200° F. Preferably, pulping fluid 47 is kept at a level thatcovers approximately ⅓ of each chamber within the fiber recoveryapparatus. Agitation due to the rotation of the chambers promotesseparation of the cellulosic fibers from any contaminants so as to forma cellulosic fiber slurry.

The first two fiber recovery apparatuses 6 and 7 are referred to as theseparation zones. Preferably, the apparatus 6 referred to as zone 1 andapparatus 7 referred to as zone 2 includes nine cells each, and theapparatus 8 includes six cells referred to as zone 3. Pulping fluid 47utilized in the separation zones 1 and 2 is preferably circulated in aclosed loop that includes a series of one or more untreated white water50 holding tanks 16, 17 and 18 (one or more of which may include steaminjection). Pulping fluid 47 used in the fiber recovery apparatus 6, 7and 8 and white water 49 pressed from the cellulosic fibers in the pulpdewatering presses 27, as manufactured by Fields & Boyd Wedge Belt Press(model #XLWT-80) and 28, as manufactured by Rietz (60 inch V-Press)includes various inorganic chemicals such as clays, calcites, talc,fluorspar, feldspar and other contaminates such as metals, glass,minerals and plastics that are released from the waste during thepulping process. White water 49 is processed thorough one or morehydro-cleaners 10, as manufactured by Black-Clawson (HD Cleaner). Dirtywater 48 is processed through water clarifiers 15, as manufactured byBeloit ((DAF Clarifier), to which are added selected promoter andcollector reagents and polymers comprising of crude or refined fattyacids, petroleum sulfonates, sulfonated fatty acids, fatty amines andamine salts at dosages of about 0.1 to about 2.0 pounds per ton of wastematerials processed to selectively remove fine contaminants 19 (such asclay, other inorganic material, and ultra fine organic fibers) fromdirty water 48 that is then pumped to storage tank 20, and a sludgepress 21 as manufactured by Andritz (Andritz 0.3 Meter Press), fordisposal to a landfill 23. The rate of removal of the above describedcontaminants at water clarifier 15 is based on the density and finescontent of the final product (after packaging 32) that is measured usingconventional methods such as ASTM C-739 for determining the settleddensity of cellulosic insulation and TAPPI T-413 for determining the ashcontent of paper pulp.

Pulping fluid 47 additionally preferably comprises water containing fireretardant (FR) chemicals 24, dyes, insecticides, biocides, surfactantsand decay inhibitors [as listed in Table III] that are added in solutionutilizing a chemical dissolver or chemical add feeder apparatus 25preferably fed with steam and make-up water. The fire retardantchemicals and other chemicals are preferably absorbed by the cellulosicfibers to provide a finished product that, after packaging system 32,meets federal requirements ASTM C-739, C-1149, C-1497, CPSC 16 CFR209and 1404 for product performance with a total ash content equal to orless than 10%, and preferably an average, with an ash content of about8.09%.

The solid waste material moves through the washing chambers in theextraction zone 3, fiber recovery apparatus 8 where the plastics, glassmetal foil and other contaminates are separated from the cellulosicfibers.

From the last chamber in zone 2, fiber recovery apparatus 7, the wastematerial is transferred to the first chamber in zone 3, fiber recoveryapparatus 8, that is referred to as the extraction zone. The cellulosicfiber slurry that has been transferred into the first and succeedingchambers of zone 3 of the fiber recovery apparatus 8 are washed withinzone 3, apparatus 8, and the separated cellulosic fibers are permittedto pass through perforations in the drums of the chambers of zone 3fiber recovery apparatus 8 in a (preferably) 1%-2% cellulose fiberslurry for further processing. The remaining material (comprising largerinorganic contaminants that remain in the extraction zone 3, fiberrecovery apparatus 8) are transferred out of the last chamber fordisposal to a landfill 23. Dirty water 48 at 120° F. is preferablyoutput from fiber recovery apparatus 7 to a dirty water tank 22, whereit may be processed with or separately from untreated white water 50stored in tanks 16, 17, and 18.

The cellulosic fiber slurry that has been filtered through theperforations in the chambers of zone three, apparatus 8, of the fiberrecovery apparatus is transferred into an extract tank (stock tank) 9for further processing. The cellulosic slurry is transferred from thestock tank 9, through the hydro-cleaner 10, which de-waters (“de-waters”being used generally to describe the process of removing all liquids(not just water) present in the cellulosic slurry) the cellulosicslurry, as manufactured by Black-Clawson (HD Cleaner), to a disk refiner11, as manufactured by Ring-R (model 48-S), which fluffs (or de-lumps)the fiber bundles following the de-watering that occurs in hydro-cleaner10. The de-lumped fiber cellulosic slurry is then transferred to aslurry thickener 12, as manufactured by Black Clawson (48.times.144Thickener), where the percentage of cellulosic fibers within the slurryis increased from a first range of about 1.5% to about 2.0% to a secondrange of about 3.0% to about 4.5% for further processing. The thickenedcellulosic fiber slurry is then transferred into a stock chest (or stocktank) 14 that holds the cellulosic slurry prior to feeding the pulpdrying and packaging process (to be described below). The thickenedcellulosic fiber slurry is transferred from the stock tank 14 to apulping fluid extractor 27, as manufactured by Fields and Boyds (WedgeBelt Press XLWT-80) (FIG. 2), and to a water press 28, as manufacturedby Rietz (V-Press), where liquid—in this case, untreated white water50—is pressed out of the slurry so that the remaining material comingout of the pulping fluid extractor and the pulp press is about 40% toabout 60% solids. This remaining material is referred to herein as“cellulosic fiber wet lap”.

An optional FR spray station (second chemical add station) 26 can beprovided after the pulping fluid extractor 27, for example, by sprayingthe cellulosic fiber wet lap with additional chemicals that includeliquid flame retardants, dyes, insecticides and/or biocides that havebeen dissolved in water (see above, Table III: Pulping FluidComposition). The amount of chemical sprayed on the cellulosic fiber wetlap is based on final product quality and various product performancerequirements. The final cellulosic insulation 33 of the preferredembodiment has a flame retardant chemical loading of approximately 6%that is well below the current industry standard using a predominatelydry process of 10% to 20%.

The cellulosic fiber wet lap is conveyed from the optional chemicalspray station 26 to a pulp press 28, as manufactured by Rietz (V-Press),and then to a fluffer 29, as manufactured by Sprout-Bauer (refiner#DM-36), that fluffs the cellulosic fiber wet lap from a first densityrange of about 6 to about 10 lbs per cubic foot to a second densityrange of about 2 to about 4 lbs per cubic foot with a moisture contentof about 40% to about 60%.

The fluffed cellulosic fiber wet lap is then conveyed to a disk refiner30, as manufactured by Ring-R (attrition mill model 48-S). Disk refiner30 aids in fluffing (i.e., de-lumping) the fiber bundles following thede-watering processes and thus improves the efficiency of the dryingprocess that follows the disk refiner 30. The method described hereinfirst fluffs the fibers to, in turn, break up the wet lap, and maintainsa fibrous surface with a preferred density of 2-6 p.c.f. This process isused to size the individual fibers to the desired length ofapproximately 0.700 mm. The preferred density of 2-6 p.c.f. issignificantly lower than nodules produced from other known methods.Notably, producing a significantly less dense product is a significantfactor in minimizing the raw material, manufacturing and energy costs ofproduction. While obtaining such a lower density is a result of theunique pulping methods, dewatering methods, fluffing methods, dryingmethods, and packaging methods described herein with regard toparticular aspects of the invention, an important factor in contributingto such lower density is maintenance of a drying temperature for fluffedfibers in a second disc refiner of between 150 to 700° F., whichtemperature range is also important to reduce bacteria content and todry the fibers to a uniform dryness. As the system and method describedherein process feed stock comprised of a wide variety of waste materialsfrom various waste sources, the feed stock and any resulting fibers aremore susceptible to bacteriological growth, and the maintenance ofproper drying temperatures is important to combat such bacteriologicalgrowth. Moreover, such drying temperature is an important aspect of theprocesses described herein to enable further processing and acceptableproduct in the marketplace.

The fluffed cellulosic fiber wet lap is then to a conventionalindustrial dryer 31, as manufactured by Wolverine Proctor & Swartz(model K17305), where the dryer reduces the moisture content of thecellulosic fibers to a range of about 10% to about 18%. Dryer 31 driesthe fluffed cellulosic wet lap at a temperature between about 150° F.and about 700° F., and the output is processed cellulosic insulation 33.The processed cellulosic insulation 33 is then conveyed into atraditional packaging/baling apparatus 32.

According to an alternative embodiment of the present invention, asecond flash/tunnel dryer 31 a can be inserted prior to disk refiner 30,or, subsequent to existing flash/tunnel dryer 31. In the former case,the first dryer can be a tunnel dryer, followed by disk refiner 30,followed by flash dryer 31. In the latter case, the two dryers can bothbe the same, either flash or tunnel, or can be different (flash andtunnel). Placing the disk refiner between the two dryers refines thecellulosic fiber product at a moisture content between about 20% toabout 25%, rather than about 50%.

Untreated white water 50 extracted from pulping fluid extractor 27 andpulp press 28 is preferably transferred to untreated white water storagechest 35 to remove additional inorganic compounds such as calciumcarbonate 46, and aluminum and magnesium hydroxide 45, among others,that can be commercially sold to reduce the overall cost of the processdescribed herein. An acid 34 such as sulfuric acid, phosphoric acid, oracidic acid, among others, is preferably added to untreated white water50 in storage chest 35 to lower the pH of untreated white water 50 to arange of about 4.0 to about 5.0 so as to dissolve the inorganiccompounds listed above.

The solution is then transferred to a precipitator 37, as manufacturedby US Filter (models 001 through 012 depending on production capacityrequired). Alkaline agents 36 such as sodium tetraborate, sodiumborates, calcium borates, ammonium hydroxide, anhydrous ammonia, lime,and/or soda ash, among others, are then added to the solution in theprecipitator 37 to increase the pH to a range of about 4.5 to about 6.0so as to cause precipitation of aluminum and magnesium hydroxidebyproducts 45 that are then recovered with a batch or continuous flowfilter/centrifuge 38 as manufactured by Western States Machine Company.The remaining solution is then transferred to a carbonator 40, asmanufactured by Niro Inc., where carbon dioxide 39 is added to thesolution, and the solution is then transferred to a precipitator 42, asManufactured by US Filter, where additional alkaline agents 41 such assodium tetraborate, sodium borates, calcium borates, ammonium hydroxide,anhydrous ammonia, and lime, among others, are added to increase the pHto a range of about 1.5 to about 12.8, or to a point where suitablequantities of calcium carbonate 46 will precipitate out of the solution.The solution is then pumped through a filter/centrifuge 43, asmanufactured by the Western States Machine Company, for removal of thecalcium carbonate 46. The remaining solution, hereinafter referred to astreated white water 51, is then transferred into treated white waterstorage chest 44 and re-circulated to the fiber recovery apparatus. AsFIG. 2 illustrates, treated white water 51 is combined with untreatedwhite water 50 and both are sent to white water storage chest 13.

Animal and Fowl Bedding Products

As discussed above, the system and method discussed above can also beused for the manufacture of animal and fowl bedding, with only slightmodifications in the system and method according to the embodiments ofthe present invention. The manufacturing process described above ismodified to exclude disc refiner 30 (see FIG. 2) in order to maintainadequate fiber bundles that yield a finished bulk density animal andfowl bedding product with a range in density from about 2 lbs per cubicfoot to about 6 lbs per cubic foot. The animal and fowl bedding productis also dried to a uniform moisture level of about 10% to about 18%,similarly to that as described above in regard to the manufacture ofcellulosic fiber insulation products. Mold and bacteria, which are asignificant problem with conventional wood shavings or sawdust, aresignificantly reduced when animal and fowl bedding manufacturedaccording to the embodiments of the present invention. Animal and fowlbedding products manufactured according to the embodiments of thepresent invention have consistent—and low—levels of moisture.

Another substantial advantage of the animal and fowl bedding productproduced by the system and method according to an embodiment of thepresent invention is that such animal and fowl bedding product issubstantially free of contaminants. While the animal and fowl beddingproducts manufactured according to the embodiments of the presentinvention can be made substantially free of containments, certaindesirable agents that originate in the raw materials can be left in theanimal and fowl bedding product. Furthermore, according to an embodimentof the present invention, the animal and fowl bedding product can beapplied easier than prior art bedding products. For example, animal andfowl bedding product manufactured according the system and method of thepresent invention can be applied to desired locations by a pneumaticspreading device, which is very easy and efficient to use versusmechanical or manual spreading of prior art shavings, sawdust orpellets.

Animal and fowl bedding produced according to the embodiments of thepresent invention processes waste material containing cellulosic fibersof mixed length, and creates fiber bundles that have a higher level ofmemory retention than competitors' animal and fowl bedding products,thus improving moisture holding capability, thickness for thermalbenefit and reconstitution. As a result, consumers, whether private orcommercial/industrial, will successfully endeavor to reconstitute orfluff up their bedding to allow it to dry and gain additional life fromthe animal and fowl bedding product. Animal and fowl bedding productmanufactured according to a preferred embodiment of the presentinvention incurs between about 40% to about 50% less compaction comparedto conventional paper-based animal and fowl bedding products.

Furthermore, because of the flexibility of the manufacturing processdescribed above according to several embodiments of the presentinvention, a nearly limitless amount of additives can be inserted to thefibers in such a way that the additives become part of the fibercomposition and therefore are not susceptible to separation.

Further still, manufacturing animal and fowl bedding product accordingto the embodiments of the present invention removes high levels ofinorganic components therefore providing a paper-based product that hashigher absorption qualities per pound of product, holds its structurebetter and therefore provides a higher level of thermal barrier.Compared with conventional paper-based animal and fowl bedding, theanimal and fowl bedding product manufactured according to an embodimentof the present invention, demonstrates between about 15% to about 20%higher absorption level. The animal and fowl bedding productmanufactured according to exemplary embodiments of the present inventionhas improved moisture absorption capabilities because of the higher ashcontent as compared to known animal and fowl bedding products.

According to a preferred embodiment of the present invention, animal andfowl bedding product manufactured according to the processes and systemdescribed herein, with the modification of subjection of the product toa step that includes applying heat (or drying) at a temperature betweenabout 250° F. and about 350° F., provides a product that substantiallyreduces the ability for mold and bacteria to grow on the animal and fowlbedding. According to a preferred embodiment of the present invention,the fibers are dried at a temperature above about 300° F. Otheradvantages of animal and fowl bedding manufactured according to theprocesses and system described herein includes: substantially higherabsorbency than wood shavings, sawdust or straw (e.g., in the order ofabout 4 to about 6 times greater absorbency); substantially higherabsorbency than conventional paper-based bedding (e.g., in the order ofabout 18% to about 25% greater absorbency); a uniform and consistentlymanufactured product; and an animal and fowl bedding product wherein theparticle size and its composition improves longevity in the product.Further still, other advantages include reductions in the amount of footsores and other ailments linked to wood based bedding; improved thermalqualities; faster decomposition when properly disposed of; and an animaland fowl bedding product that is substantially free from contamination,and one that can be custom manufactured to include performance enhancers(for example, scents, colors, among others). In addition, animal andfowl bedding product manufactured according to the processes and systemdescribed herein comes packaged for clean and dry storage and isacceptable for decomposition in fields or for biomass power generation.

CONCLUSION

Thus, what has been described is an efficient system and process bywhich previously unrecoverable waste products are turned into usefulfiber products, such as cellulosic insulation, and animal and fowlbedding, among other products such as industrial fibers where fibers areused as thickeners, absorption agents or fillers and hydro-mulch, with atotal ash content equal to or less than 10%.

The individual components shown in outline or designated by blocks inthe attached Drawings are all well-known in the waste recycling arts,and their specific construction and operation are not critical to theoperation or best mode for carrying out the invention.

While the present invention has been described with respect to what ispresently considered to be the preferred embodiments, it is to beunderstood that the invention is not limited to the disclosedembodiments. To the contrary, the invention is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims. The scope of the following claims is to beaccorded the broadest interpretation so as to encompass all suchmodifications and equivalent structures and functions.

Any U.S. and foreign patent document discussed above is herebyincorporated by reference into the detailed Description of the PresentlyPreferred Exemplary Embodiments.

1. A process for recovering organic cellulosic fibers from landfillmaterials such as post consumer, municipal and industrial wastematerials comprising: a. selectively introducing waste materialscontaining organic cellulosic fibers into a size reduction machinewithout prior fluid pre-conditioning of said waste materials; b.conveying such waste material from said size reduction machine to atank, drum or tunnel type fiber recovery apparatus; and c. subjectingsuch waste material for a selected period of time to simultaneousmechanical and fluid fiberization in said fiber recovery apparatus. 2.The process of claim 1 further comprising: d. introducing a pulpingfluid containing chemicals to enhance the fiber separation process; e.selectively treating the recovered fibers with rapidly penetrating flameretardants, insecticidal chemicals and decay inhibitors; f. selectivelydyeing the separated fibers to selected colors; and, g. providing solidsseparation reagents to selectively remove contaminants in the pulpingfluids.
 3. The process of claim 2 where the pulping fluid is selectivelyheated to a temperature range between about 50° F. to about 200° F., andwherein said simultaneous mechanical and fluid fiberization is carriedout at a temperature between about 50° F. and about 200° F.
 4. Theprocess of claim 1 further comprising: h. cleaning the recovered fibersthrough screening and hydro-cleaning devices to remove plastics andtramp metal; i. conveying the removed plastics and tramp metals to awaste disposal system consisting of a receiving tank and a sludge press;and j. extracting a high percentage of the pulping fluid for furtherprocessing including for reuse as a pulping medium.
 5. The process ofclaim 1 further comprising: k. subjecting the recovered fibers to amechanical disk refiner to control fiber length, fiber bundle separationand fiber surface properties.
 6. The process of claim 1 furthercomprising: l. removing contaminants consisting of fillers, fines,coatings and other extraneous materials through the use of one or moreclarifiers with select solids separation reagents and polymers.
 7. Theprocess of claim 1 further comprising: m. extracting pulping fluids andwater from the recovered fibers to formulate a cellulosic fiber wet lapof about 40% to about 60% pulp solids content; n. fluffing thecellulosic fiber wet lap in a cake fluffer and a disk refiner; o. dryingthe fluffed fibers in a flash or tunnel dryer; and p. conveying thedried fibers to a packaging or baling system.
 8. The process accordingto claim 7, wherein the step of drying comprises: drying the fluffedfibers at a temperature from about 150° F. to about 700° F., therebyreducing bacteria content of the recovered fibers, and drying them to auniform moisture content.
 9. The process according to claim 8, whereinthe moisture content is between about 10% and about 18%.
 10. The processaccording to claim 8, wherein the dried fibers have a bulk density ofbetween about 2 pounds per cubic foot to about 6 pounds per cubic foot.11. The process according to claim 8, wherein said drying step producesdried fibers configured for use as animal and fowl bedding and have ahigher degree of absorbency than sawdust, straw, wood shaving, orconventional paper-based bedding.
 12. The process according to claim 11,wherein the dried fibers are about six times more absorbent thansawdust, straw or wood shavings.
 13. The process according to claim 11,wherein the dried fibers are between about 18 percent and 25 percentmore absorbent than conventional paper-based bedding.
 14. The processaccording to claim 8, wherein said drying step produces dried fibers areconfigured for use as animal and fowl bedding and incur between about40% to about 50% less compaction than conventional paper-based animaland fowl bedding.
 15. The process of claim 7, further comprising: q.removing inorganic precipitated chemicals and contaminants from theextracted pulping fluids; and r. recycling the pulping fluids back tothe primary tank/drum/tunnel fiber recovery apparatus.
 16. The processof claim 15 where the removed inorganic precipitated chemicals andselected contaminants are selected from the group consisting of calciumhydroxide, calcium carbonate calcites, aluminum hydroxide, aluminumoxide, magnesium hydroxide, and various other minor hydroxides.
 17. Theprocess according to claim 1, wherein the recovered organic cellulosicfibers comprise a final total ash content equal to or less than about10%.
 18. The process according to claim 1, wherein the recovered organiccellulosic fibers comprise a final total ash content of about 8.09%. 19.The process according to claim 1, wherein the recovered organiccellulosic fibers comprise an average fiber length greater than about0.700 mm.
 20. The process according to claim 1, wherein the recoveredorganic cellulosic fibers comprise an average fiber length of about0.780 mm.